Programmable Cartridge-Style Hydraulic Flow Sensor

ABSTRACT

A cartridge-style flow sensor for sensing fluid flow within a manifold. The sensor includes an exterior, interior, a circuit board, and first and second ports. The first and second ports permit fluid to flow into and out of the interior. A Hall Effect Sensor in the interior detects the number of revolutions of an impeller. An electric coupler interfaces with the sensor and a transmitter for communication of the revolutions of the impeller to a controller. The controller determines the rate of fluid flow in a conduit. The controller automatically issues a command signal to a component of a hydraulic system to alter the rate of fluid flow in the conduit. The cartridge hydraulic flow sensor is easily and releasably engaged to a cavity of a hydraulic circuit manifold.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation-in-Part and claims the benefit ofU.S. patent application Ser. No. 18/122,230 filed Mar. 16, 2023. U.S.patent application Ser. No. 18/122,230 filed Mar. 16, 2023 is acontinuation of U.S. patent application Ser. No. 17/146,918 filed Jan.12, 2021, issued as U.S. patent Ser. No. 11/614,351 on Mar. 28, 2023.U.S. patent application Ser. No. 17/146,918 filed Jan. 12, 2021, claimsthe benefit of U.S. Provisional Patent Application Ser. No. 63/006,157filed Apr. 7, 2020, all of which being incorporated by reference intheir entireties.

This application also claims the benefit of U.S. Provisional PatentApplication Ser. No. 63/408,178 filed Sep. 20, 2022 which isincorporated by reference in its entirety.

FIELD OF THE INVENTION

The invention is directed to a cartridge style hydraulic flow sensor forengagement into, and for removal from, a hydraulic circuit manifold. Thecartridge style hydraulic flow sensor may be electrically engaged to andin communication with a controller and/or processor to monitor fluidflow through a hydraulic circuit manifold. The cartridge style hydraulicflow sensor assists the controller in the automatic adjustment of asetting of a pumping or hydraulic system to provide for a desired volumeof liquid flowing through the hydraulic circuit manifold.

BACKGROUND

In the past hydraulic flow sensors have been difficult to incorporateinto a hydraulic system. In the past a hydraulic line has been requiredto be cut and a hydraulic flow sensor sealed within the artificiallycreated gap within the hydraulic line. The insertion of a hydraulic flowsensor within a hydraulic line naturally required labor intensiveactivities as well as skill to plumb the hydraulic flow sensor into thehydraulic line while maintaining the integrity of the hydraulic line andpreventing leakage of fluid.

Simultaneously with the modification to an existing hydraulic line,wires were required to be added proximate to the hydraulic line so thatcommunication would be established between the inserted hydraulic sensorand a display unit and control unit. The display unit frequentlyincluded components to translate the fluid flow rate into an analog ordigital signal. However, adjustment to the flow within a hydraulicsystem required an individual to manipulate a hydraulic system controlunit on a different control panel in order to effectuate a change in therate of fluid flow within the hydraulic system.

Another problem with the known prior art was the difficulties tomaintain and/or replace a conventional hydraulic flow sensor which hadbeen previously plumbed into a hydraulic line. In the past to maintainor replace a hydraulic flow sensor an individual was required to cut anexisting hydraulic flow sensor out of an existing hydraulic line inorder to access, reconfigure, repair and/or replace the non-performingor defective hydraulic flow sensor.

In addition to the drawbacks identified above, no known hydraulic flowsensor exists which is easily engaged or disengaged from a hydrauliccircuit manifold and which simultaneously provides communication with acontroller/processor which may sense fluid flow and performance within ahydraulic line or hydraulic system and which may automatically adjustthe hydraulic system to provide a desired level of performance.

The art referred to and/or described above is not intended to constitutean admission that any patent, publication or other information referredto herein is “prior art” with respect to this invention. In addition,this section should not be construed to mean that a search has been madeor that no other pertinent information as defined in 37 C.F.R. § 1.56(a)exists.

All U.S. patents and applications and all other published documentsmentioned anywhere in this application are incorporated herein byreference in their entireties.

Without limiting the scope of the invention, a brief description of someof the claimed embodiments of the invention is set forth below.Additional details of the summarized embodiments of the invention and/oradditional embodiments of the invention may be found in the DetailedDescription of the Invention below.

A brief abstract of the technical disclosure in the specification isprovided for the purposes of complying with 37 C.F.R. § 1.72.

GENERAL DESCRIPTION OF THE INVENTION

In at least one embodiment, the cartridge style hydraulic flow sensor isconveniently inserted within and/or removed from a hydraulic circuitmanifold. The cartridge style hydraulic flow sensor is simultaneouslyeasily coupled to a controller/processor used to monitor the operationalperformance of a hydraulic fluid circuit. A pump or other component maybe automatically adjusted after the operational performance of thehydraulic system is determined based on information received from thecartridge style hydraulic flow sensor.

In some embodiments, the cartridge style hydraulic flow sensor includesan impeller engaged to a shaft. A sensing element may be proximate tothe impeller in order to detect the revolutions of the impeller over aperiod of time. The sensing element may include magnets. A Hall EffectSensor may be in communication with a programmable logic controller fora hydraulic system or machine. The programmable logic controller mayanalyze the sensed rotations of the impeller and automatically adjustthe flow rate of fluid passing through a fluid conduit and hydrauliccircuit manifold.

In at least one embodiment, the cartridge style hydraulic flow sensor isbidirectional, and may sense fluid passage from opposite directions whenengaged to a hydraulic circuit manifold.

In some embodiments, the cartridge style hydraulic flow sensor may beengaged to a hydraulic circuit manifold from a vertical or horizontaldirection, or from any desired angle.

In some embodiments, the impeller may be engaged to a shaft which inturn is engaged to a gear. A Hall Effect Sensor may be used to sense,record and communicate the revolutions of the gear in order to determinethe status and/or performance of a hydraulic system.

In at least one embodiment, the programmable logic controller may be incommunication with a remotely located processor/controller which mayinterface with an operator of a hydraulic system or machine. Theremotely located processor/controller may be in communication withpumps, fluid sources, valves or other components of a hydraulic systemor machine to manually or automatically adjust the operationalparameters of the hydraulic system or machine.

In at least one embodiment, the cartridge style hydraulic flow sensorincludes an interior, at least one inlet port, and at least one outletport. The impeller may be positioned proximate to and between the inletport and the outlet port.

In at least one embodiment, the cartridge style hydraulic flow sensorincludes a rotational detector and a rotational transmitter being incommunication with either a programmable logic controller or a remotelylocated processor/controller.

In at least one embodiment, the rotational transmitter will be incommunication with either a programmable logic controller and/or aremotely located processor/controller through a hardwire connection orthrough the use of Bluetooth or Wi-Fi.

In some embodiments, the cartridge style hydraulic flow sensor may beinserted into and engaged within a hydraulic circuit manifold, or may beplaced within a hydraulic fluid line.

In at least one embodiment, the cartridge style hydraulic fluid sensormay include a check valve limiting fluid flow to a single direction.

In another alternative embodiment, a cartridge hydraulic flow sensorincludes a cylindrical casing comprising an exterior, an interior, anoutlet section, and a base, the casing having a first port and a secondport through the casing, the first port and the second port permitting afluid to flow into the interior and out of the interior, the first portbeing proximate to the base and the second port being in the outletsection, a Hall Effect Sensor is disposed in the interior, the HallEffect Sensor being proximate to the second port, the Hall Effect Sensordetecting a number of revolutions of a rotatable impeller rotating abouta shaft during a period of time, the rotatable impeller being engaged toa shaft support having the shaft, the impeller revolving about the shaftfollowing contact with the flow of the fluid, and a cover having acommunication connector, the communication connector being incommunication with a circuit board, the circuit board being incommunication with the Hall Effect Sensor, wherein the Hall EffectSensor communicates to the circuit board the detected number ofrevolutions of the impeller about the shaft during the period of time,the circuit board being constructed and arranged to compare the detectednumber of revolutions of the impeller about the shaft during the periodof time to data stored on the circuit board, the circuit boardcommunicating to the communication connector at least one of thedetected number of revolutions of the impeller about the shaft duringthe period of time, the detected number of revolutions of the impellerabout the shaft during the period of time exceeding the data, and thedetected number of revolutions of the impeller about the shaft duringthe period of time being less than the data, and further wherein thecylindrical casing is constructed and arranged for insertion into acavity of a manifold, the cavity being in fluid flow communication witha manifold conduit, the head being proximate to a manifold exterior andthe base being disposed in a manifold interior, the first port and thesecond port being in fluid flow communication with the manifold conduit.

In some embodiments the circuit board further includes a receivingconnector, a plurality of connection wires, and an interface connectorconnected to the connection wires.

In at least one embodiment, the circuit board further includes aselector switch, a microprocessor and memory.

In at least one alternative embodiment, data is stored on the memory andthe microprocessor compares the detected number of revolutions of theimpeller about the shaft during the period of time to the data.

In another alternative embodiment, the data comprises a plurality ofindividual fluid flow information parameters, and further wherein theselector switch directs the microprocessor to at least one of theplurality of individual fluid flow information parameters.

In some embodiments, the interior further includes at least one of asensor shoulder, a circumferential head groove, and a circuit boardshoulder.

In at least one embodiment, the exterior further includes at least oneof a first seal channel and a second seal channel.

In at least one alternative embodiment, the at least one casing exteriorseal is disposed in at least one of the first seal channel and thesecond seal channel.

In another alternative embodiment, the Hall Effect Sensor additionallyincludes an exterior the Hall Effect Sensor exterior having at least oneof a third seal channel and a fourth seal channel.

In some embodiments, at least one Hall Effect Sensor exterior seal isdisposed in at least one of the third seal channel and the fourth sealchannel.

In at least one embodiment, the interior has the circuit board shoulder,the circuit board engaging the circuit board shoulder.

In at least one alternative embodiment, the circuit board has at leastone slot passage.

In another alternative embodiment, the shaft support has a base collar,at least two spindle supports, and a central column.

In some embodiments, the interior has the sensor shoulder, the HallEffect Sensor exterior having a lower sensor ledge, the lower sensorledge engaging the sensor shoulder.

In at least one embodiment, the Hall Effect Sensor exterior has a headnub, the head nub engaging the circumferential head groove.

In at least one alternative embodiment, the cartridge hydraulic flowsensor includes a pressure sensor, the pressure sensor being disposed inthe interior, the pressure sensor detecting fluid pressure within themanifold conduit.

In another alternative embodiment, the cartridge hydraulic flow sensorincludes a temperature sensor disposed in the interior, the temperaturesensor detecting a temperature of the fluid within the interior.

In some embodiments, the circuit board communicates at least two of thedetected number of revolutions of the impeller about the shaft, thedetected fluid pressure within the manifold conduit, and the detectedtemperature of the fluid within the interior.

In at least one embodiment, the circuit board automatically communicatesa command signal to at least one component of a hydraulic system formodification of at least one of a rate of fluid passage, the detectedfluid pressure within the manifold conduit, and the detected temperatureof the fluid within the interior.

These and other embodiments which characterize the invention are pointedout with particularity in the claims annexed hereto and forming a parthereof. However, for further understanding of the invention, itsadvantages and objectives obtained by its use, reference should be madeto the drawings which form a further part hereof and the accompanyingdescriptive matter, in which there is illustrated and describedembodiments of the invention.

Various other objects, features and attendant advantages of the presentinvention will become fully appreciated as the same becomes betterunderstood when considered in conjunction with the accompanyingdrawings, in which like reference characters designate the same orsimilar parts throughout the several views, and wherein:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevation view of one alternative embodiment of thecartridge style hydraulic flow sensor;

FIG. 2 is a cross-sectional side view of one alternative embodiment ofthe cartridge style hydraulic flow sensor taken along the line 2-2 ofFIG. 1 ;

FIG. 3 is an exploded perspective view of one alternative embodiment ofthe cartridge style hydraulic flow sensor;

FIG. 4 is a cut-away view of one alternative embodiment of the cartridgestyle hydraulic flow sensor;

FIG. 5 is an alternative cross-sectional side view of one embodiment ofthe cartridge style hydraulic flow sensor taken along the line 2-2 ofFIG. 1 , as engaged to a hydraulic circuit manifold;

FIG. 6 is a detail schematic diagram of one embodiment of a gear incommunication with a Hall Effect Sensor of the cartridge style hydraulicflow sensor;

FIG. 7 is a perspective view of one alternative embodiment of thecartridge style hydraulic flow sensor engaged to a hydraulic circuitmanifold;

FIG. 8 is a schematic diagram of one alternative embodiment of thecartridge style hydraulic flow sensor within a hydraulic system;

FIG. 9 is a schematic diagram of one alternative embodiment of thecartridge style hydraulic flow sensor within a hydraulic system;

FIG. 10 is a schematic diagram of one alternative embodiment of thecartridge style hydraulic flow sensor within a hydraulic system;

FIG. 11 is a circuit diagram of the electronic circuit of onealternative embodiment of the cartridge style hydraulic flow sensor;

FIG. 12 is a side elevation view of one alternative embodiment of theprogrammable cartridge style hydraulic flow sensor;

FIG. 13 is a cross-sectional side view of one alternative embodiment ofthe programmable cartridge style hydraulic flow sensor taken along theline 13-13 of FIG. 19 ;

FIG. 14 is a top plan view of one alternative embodiment of theprogrammable cartridge style hydraulic flow sensor taken along the line14-14 of FIG. 13 ;

FIG. 15 is a cross-sectional top view of one alternative embodiment ofthe programmable cartridge style hydraulic flow sensor taken along theline 15-15 of FIG. 13 ;

FIG. 16 is a cross-sectional top view of one alternative embodiment ofthe programmable cartridge style hydraulic flow sensor taken along theline 16-16 of FIG. 13 ;

FIG. 17 is a cross-sectional top view of one alternative embodiment ofthe programmable cartridge style hydraulic flow sensor taken along theline 17-17 of FIG. 13 ;

FIG. 18 is a cross-sectional top view of one alternative embodiment ofthe programmable cartridge style hydraulic flow sensor taken along theline 18-18 of FIG. 13 ; and

FIG. 19 is an exploded perspective view of one alternative embodiment ofthe programmable cartridge style hydraulic flow sensor.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1 through FIG. 4 the cartridge style hydraulic flowsensor is in general referred to by reference numeral 20. The cartridgestyle hydraulic flow sensor 20 is preferably releasably coupled to acavity 54 of a hydraulic circuit manifold 56. (FIG. 5 and FIG. 7 )

In at least one embodiment, the cavity 54 includes internal threadsproximate to the outer surface of the hydraulic circuit manifold 56. Thecartridge style hydraulic flow sensor 20 includes mating threads 58which engage the threads of the cavity 54 to secure the cartridge stylehydraulic flow sensor 20 within the hydraulic circuit manifold 56.

In an alternative embodiment, the interior of the cavity 54 is a smoothbore and does not include any internal threads. In this embodiment, thecartridge style hydraulic flow sensor 20 may be inserted within thecavity 54 and may be secured within the cavity 54 through the use of acap. The cap may be threaded or otherwise affixed to the exterior of thehydraulic circuit manifold 56 covering the top of the cartridge stylehydraulic flow sensor 20.

In at least one embodiment, the cartridge style hydraulic flow sensor 20includes a body 40 which is exterior to the hydraulic circuit manifold56 following engagement of the cartridge style hydraulic flow sensor 20within the cavity 54. The body 40 may be used to tighten the engagementbetween the mating threads 58 and the internal threads of the cavity 54.

In at least one embodiment, a head 60 extends upwardly from the body 40.The head 60 preferably includes a circular ledge 62 descending from theupper surface of the head 60 downwardly towards the body 40. Thecircular ledge 62 preferably receives a platform 50 which may bereleasably secured to the head 60 by the use of a mechanical fastener,one example of which is a screw.

In one embodiment, the platform 50 includes a electronic coupler 64which preferably includes power/communication leads 72 and a transmitter38.

In one alternative embodiment, a cylindrical casing 66 extendsdownwardly from the body 40 and mating threads 58 towards a base 68. Thebase 68 may include a groove receiving an elastic base O-ring 70. Anupper portion of the cylindrical casing 66 preferably includes aplurality of outlet fluid conduits 22. In some embodiments the outletfluid conduits 22 pass through the cylindrical casing 66 above theimpeller 42.

In at least one embodiment, fluid enters the cartridge style hydraulicflow sensor 20 from below or proximate to the base 68 as represented byarrow 78. The fluid moves upwardly within cylindrical casing 66 pastimpeller 42 and exits the cartridge style hydraulic flow sensor 20through the plurality of outlet fluid conduits 22 and into a fluidconduit within the hydraulic circuit manifold 56.

In an alternative embodiment, the outlet fluid conduits 22 may be aninlet fluid conduit when liquid enters the cartridge style hydraulicflow sensor 20 in an opposite direction as related to arrow 78. Thefluid will then exit the cartridge style hydraulic flow sensor 20proximate to base 68.

With reference to FIG. 2 , the electronic coupler 64 extends downwardlyfrom the top of head 60 into the interior of the cartridge stylehydraulic flow sensor 20. The leads 72 extend downwardly for engagementto a circuit board 48 which may be a printed circuit board including aprogrammable logic controller.

In at least one embodiment, the circuit board 48 is positioned above,and is in communication with a Hall Effect Sensor 52. A shaft 74preferably extends downwardly from the Hall Effect Sensor 52 towards thebase 68. An impeller 42 is preferably rotatably engaged to the shaft 74.The impeller 42 preferably includes a plurality of shaped fins or bladeswhich freely rotate relative to the shaft 74 upon exposure to a passingfluid flow. In one embodiment, the impeller 42 may include internalbearings for engagement to the shaft 74, to facilitation free rotationbetween the impeller 42 and shaft 74.

In at least one embodiment, at least one of the shaped fins or blades ofthe impeller 42 include or are embedded with a magnetic material.Rotation of the impeller 42 is sensed by the Hall Effect Sensor 52 wherethe Hall Effect Sensor 52 counts the revolutions of the impeller 42during a pre-established period of time. The counted revolutions of theimpeller 42 are communicated from the Hall Effect Sensor 52 to thecircuit board 48. Circuit board 48 will then receive, analyze, andcompare the number of revolutions of the impeller 42 to pre-stored dataof impeller revolutions, for communication to a remotecontroller/processor 76 having an interface with an operator.Alternatively, the circuit board 48 may activate the transmitter 38 forre-communication of the sensed impeller revolutions for processing andanalysis at the remote controller/processor 76.

In at least one embodiment, one or more O-rings 44 may be placed intogrooves in the exterior surface of the Hall Effect Sensor 52. TheO-rings 44 assist to establish a fluid seal between the Hall EffectSensor 52 and the interior surface of the cylindrical casing 66, or themating threads 58. In one embodiment, the base O-ring 70 is used toestablish a fluid seal between the base 68 and the interior surface of acavity 54.

In at least one embodiment, as shown in FIG. 3 , a positioning ring 80may be located between the top of the Hall Effect Sensor 52 and thebottom of the platform 50 in surrounding engagement relative to thecircuit board 48. FIG. 3 also shows that platform 50 has an centralopening 82 which receives the electronic coupler 64.

In at least one embodiment, the cartridge style hydraulic flow sensor 20is formed of an exterior structure which includes the head 60, circularledge 62, body 40, mating threads 58, cylindrical casing 66 and base 68.An interior assembly is formed of the electronic coupler 64, platform50, circuit board 48, Hall Effect Sensor 52, shaft 74 and impeller 42.The interior assembly is preferably positioned within the interior ofthe exterior structure, and is secured to the exterior structure by aplurality of mechanical fasteners which may be screws passing throughthe platform 50 and into the head 60.

In one embodiment as depicted in FIG. 3 , the electric/communicationleads 72 extend from the electronic coupler 64 to the circuit board 48.The circuit board 48 may also be in communication with the transmitter38 which is used to communicate information or data to the remotecontroller/processor 76. In some embodiments, the impeller 42 isrotatably disposed on a shaft 74 where the impeller 42 is adjacent tothe Hall Effect Sensor 52. In other embodiments, the shaft 74 may havean increased length dimension separating the impeller 42 from the bottomof the Hall Effect Sensor 52 by a desired dimension.

Referring to FIG. 4 , the cartridge style hydraulic flow sensor 20 isshown with a portion of the head 60, body 40, mating threads 58 andcylindrical casing 66 cut away to show the impeller 42, Hall EffectSensor 52, circuit board 48 and electronic coupler 64. As shown in FIG.4 the impeller 42 is adjacent to the bottom of the Hall Effect Sensor52.

In at least one embodiment, the impeller 42 may freely rotate aboutshaft 74 in either a clockwise or counterclockwise direction dependenton the direction of the fluid flow within a hydraulic circuit manifold56. The direction of the revolution of the impeller 42 on the shaft 74may alternatively be dependent upon the initial direction or orientationselected for the blades or fins.

In at least one embodiment, the cartridge style hydraulic flow sensor 20is not required to couple to the hydraulic circuit manifold 56 in avertical orientation. The cartridge style hydraulic flow sensor 20 mayalso be coupled to the hydraulic circuit manifold 56 in a horizontaldirection, or an angular direction relative to either a vertical or ahorizontal direction to sense fluid flow passage through a fluid conduitwithin the hydraulic circuit manifold 56.

The hydraulic circuit manifold 56 may be simple or very complex. In someembodiments the hydraulic circuit manifold 56 may include any number ofvalves 96, outlet fluid conduits 22, or inlet fluid conduits 26 and/orinternal fluid flow conduits as required for a particular application. Acartridge style hydraulic flow sensor 20 may be in fluid flowcommunication within any desired conduit of a hydraulic system 84.

Fluid within the hydraulic circuit manifold 56 may flow upwardly asrepresented by arrow 78, contacting and rotating the blades or fins ofthe impeller 42, and then passing outwardly through the outlet fluidconduit 22 into a fluid flow conduit of the hydraulic circuit manifold56.

As shown in FIG. 4 the circuit board 48 and transmitter 38 are proximateto the electronic coupler 64 and leads 72. In addition, the circuitboard 48 is also proximate to the top of the Hall Effect Sensor 52.

In at least one embodiment, the Hall Effect Sensor 52 is connectedelectrically and is in communication with the circuit board 48 andtransmitter 38. The circuit board 48 and transmitter 38 are alsoelectrically connected and are in communication with the electroniccoupler 64. The electronic coupler 64 through the use of the leads 72 iselectrically connected and is in communication with an electrical powersource and a remote controller/processor 76. The remotecontroller/processor 76 receives from circuit board 48 the sensed orcalculated revolutions of the impeller 42 over the period of time.

The remote controller/processor 76 then performs an analysis of thereceived revolutions of the impeller 42 over the period of time, andinserts the number of revolutions of the impeller 42 into an equationfor processing. The remote controller/processor 76 may also compare thereceived revolutions of the impeller 42 against pre-stored data. Theremote controller/processor 76 determines the operational state of ahydraulic system 84. In general, the hydraulic system 84 will at leastinclude a hydraulic circuit manifold 56 as well as a cartridge stylehydraulic flow sensor 20 and a pump 86.

In some embodiments, the hydraulic circuit manifold 56 may receive acommunication or command signal from a remote controller/processor 76which in turn may open or close one of a plurality of valves 96 incommunication with fluid flow conduits within the hydraulic circuitmanifold 56. The communication between the cartridge style hydraulicflow sensor 20 and the remote controller/processor 76 enables anoperator to determine if an adjustment is required to be made to theoperational parameters of the pump 86 to increase or decrease the rateor volume of liquid flow entering the hydraulic circuit manifold 56 tobe sensed by the cartridge style hydraulic flow sensor 20. The pump 86is also electrically connected and is in communication with the remotecontroller/processor 76. The remote controller/processor 76 in turn mayadjust a setting on the pump 86 in response to information received fromthe cartridge style hydraulic flow sensor 20 related to a fluid flowrate within the hydraulic circuit manifold 56.

The remote controller/processor 76 is not restricted to communicationsbetween the cartridge style hydraulic flow sensor 20 or hydrauliccircuit manifold 56 and pump 86. The remote controller/processor 76 mayadditionally be in communication with any other elements of an hydraulicsystem 84 or other elements of a system or structure or machine whichmay be capable of regulation, control, adjustment, initiation and/ortermination, to name a few. In addition, the remote controller/processor76 may be in communication, and may monitor all functions of a hydraulicsystem 84 in real time, including but not necessarily limited to valves,flow meters and sensors. Further, the remote controller/processor 76 mayinclude artificial intelligence software which is used to automaticallyissue command signals to components capable of control within ahydraulic system 84 to maximize fluid flow within the hydraulic system84.

In at least one alternative embodiment, the communication between thecartridge style hydraulic flow sensor 20 through the electronic coupler64 to the remote controller/processor 76 will occur through a wiredconnection. Alternatively, the connection through the electronic coupler64 to the remote controller/processor 76 may pass initially to anintermediate communication hub through a wired connection, and then maybe retransmitted by the intermediate medication hub to the remotecontroller/processor 76 through a wired connection or through a wirelessconnection such as through Bluetooth or Wi-Fi.

In an alternative embodiment, the electronic coupler 64 will includewireless communication capabilities for communication directly to theremote controller/processor 76 through a wireless media such asBluetooth or Wi-Fi or by use of another wireless communication medium.In an alternative embodiment, the electronic coupler 64 may transmit awireless communication to an intermediate communication hub. Theintermediate communication hub may than re-transmit the communication tothe remote controller/processor 76 through a wireless transmission orthrough a wired connection at the preference of an individual.

In an alternative embodiment, as shown in FIG. 5 , the impeller 42 isengaged to the shaft 74. The shaft 74 extends upwardly traversing thetop of the cartridge style hydraulic flow sensor 20 terminating with aconnection to a gear 88. The rotation of the impeller 42 in response tofluid flow within the fluid flow conduit of the hydraulic circuitmanifold 56 is translated to the rotation of the gear 88. It should benoted that the gear 88 may rotate in either a clockwise orcounterclockwise direction resulting from the factors as earlierdescribed.

In this alternative embodiment, at least one portion of the gear 88includes magnetic material which will pass a Hall Effect Sensor 52 whichis positioned proximate to the gear 88. The Hall Effect Sensor 52 willsignal the rotations of the gear 88 relative to the Hall Effect Sensor52 for communication to the circuit board 48 and transmitter 38, and fortransmission to the remote controller/processor 76 through any of thealternative communication methods earlier described.

In the alternative embodiment depicted in FIG. 5 , a cover 90 may besecurely positioned in a covering relationship relative to the gear 88in order to protect against any object or condition interfering with thefree rotation of the gear 88.

In an alternative embodiment depicted in FIG. 5 and FIG. 6 , therotation of the gear 88 as connected to the shaft 74 and impeller 42 isrepresented by arrow 92. The separation of the gear 88 from the HallEffect Sensor 52 enables the free rotation of the gear 88 relative tothe sensor. It should be noted that gear 88 may be separated from HallEffect Sensor 52 by any desired distance dependent on materials and sizedimensions selected to form the gear 88, and the magnetic materialintegrated into the gear 88.

In at least one embodiment as depicted in FIG. 5 , the cartridge stylehydraulic flow sensor 20 includes a check valve 104 within the interiorof the cylindrical casing 66. The check valve 104 functions to restrictthe direction of fluid flow inwardly from the exterior of the base 68towards the impeller 42 as depicted by reference numeral arrow 78.Alternatively, the check valve 104 functions to restrict the directionof fluid flow outwardly from the interior through the base 68 away fromthe impeller 42 as depicted by a direction opposite to reference numeralarrow 78. The check valve 104 will limit the direction of fluid flow toa single direction during use at any given time. In order to restrictthe direction of fluid flow to an opposite direction, then theorientation of the check valve 104 will be required to be reversed, orthe check valve 104 will need to be replaced. The check valve 104 may belocated at any desired distance from the impeller 42 to preventinterference with the rotation of the impeller 42 during use. The checkvalve 104 may be positioned proximate to the base 68, immediately to theexterior of the base 68, or may act as a bottom surface for thecartridge style hydraulic flow sensor 20.

FIG. 6 also identifies the electrical communication between the HallEffect Sensor 52 and the circuit board 48 and transmitter 38.

In at least one embodiment as shown in FIG. 7 , a hydraulic circuitmanifold 56 includes a number of cavities 54 each of which being influid flow communication with a fluid flow conduit traversing hydrauliccircuit manifold 56 in any desired direction.

In another alternative embodiment as depicted in FIG. 8 , a schematicdiagram of a hydraulic system 84 is shown when a cartridge stylehydraulic flow sensor is in fluid flow communication with a valve 96within a hydraulic circuit manifold 56. The valve 96 may be in electricand in communication with a remote controller/processor 76 to regulatean operational status of the hydraulic system 84. In the embodimentshown in FIG. 8 , the valve 96 is in communication with an actuator 98which in turn is in communication with remote controller/processor 76. Acommand signal is transmitted from the remote controller/processor 76for receipt by the actuator 98. The actuator 98 in turn opens, increasesthe opening, decreases the opening and/or closes the valve 96 inresponse to the received command signal.

In the embodiment depicted in FIG. 8 , the hydraulic circuit manifold 56and valve 96 are in fluid flow communication with a filter 100 and abypass valve 102. The remote controller/processor 76 may be incommunication with the bypass valve 102 in order to regulate theopening, partial opening, partial closing and/or closing of the bypassvalve 102.

In the embodiment depicted in FIG. 8 a cartridge style hydraulic flowsensor 20 is in fluid flow communication with the filter 100 and thebypass valve 102 and/or the valve 96, and hydraulic circuit manifold 56,for receipt of fluid flow from any number of fluid flow conduits.

In the embodiment depicted in FIG. 8 , the volume of fluid flowbypassing the filter 100 is an indication of the condition of the filterelement. The more a filter element gets saturated with contaminants thatare being removed from the fluid by the filter 100, the higher the rateof flow across the bypass valve 102. In this application, the cartridgestyle hydraulic flow sensor 20 can accurately monitor the condition ofthe filter element, insuring that the element is either still effective,or requires replacement.

In another alternative embodiment as depicted in FIG. 9 , a pump 86 isin fluid flow communication with a cartridge style hydraulic flow sensor20. The cartridge style hydraulic flow sensor 20 may additionally be incommunication with a valve 96 of a hydraulic circuit manifold 56 and aremote controller/processor 76. The valve 96 of the hydraulic circuitmanifold 56 is in communication with a actuator 98. The valve 96regulates the opening, partial opening, partial closing and/or closingof the valve 96 of the hydraulic circuit manifold 56. The actuator 98 isin communication with the remote controller/processor 76 and willreceive a command signal from the remote controller/processor 76directing the modification of the operational status of the valve 96.

In another alternative embodiment as depicted in FIG. 10 , a pump 86 isin fluid flow communication with a cartridge style hydraulic flow sensor20 as part of a hydraulic circuit manifold 56. Alternatively, thecartridge style hydraulic flow sensor 20 may be directly plumbed into ahydraulic line. The cartridge style hydraulic flow sensor is incommunication with the remote controller/processor 76 which may be usedto monitor the operational status of the hydraulic system 84 and toissue a communication signal to an operator in the event that the statusof a hydraulic system 84 moves outside of an acceptable operationalparameter. Alternatively, the remote controller/processor 76 mayautomatically send command signals to the pump 86 to maintain theoperational status of hydraulic system 84 as sensed by the cartridgestyle hydraulic flow sensor 20.

The cartridge style hydraulic flow sensor 20 may be used as a componentin a hydraulic system 84 which may have the representative function ofmonitoring hydraulic flow output; monitoring flow within a steering orbreak system for a vehicle; monitoring flow across a relief valve; ormonitoring flow in a pump case drain. The above uses have been providedfor illustrative purposes and should in no way be considered as limitingof the available uses of a cartridge style hydraulic flow sensor 20within a fluid system or machine.

It should be noted that the hydraulic system 84 depicted in FIG. 8through FIG. 10 represent an extremely small number of examples of thealmost infinite number of hydraulic systems 84 which may include the useof a cartridge style hydraulic flow sensor 20 to monitor and signal thestatus of fluid flow through fluid flow conduits. The examplesidentified in FIG. 8 through FIG. 10 are not to be construed as in anyway limiting of the use of the cartridge style hydraulic flow sensor 20.

In one alternative embodiment, a circuit diagram is provided for thecartridge style hydraulic flow sensor 20 in FIG. 11 . In one embodimentof the circuit used in the cartridge style hydraulic flow sensor 20,electrical pulse signals are converted from the Hall Effect Sensor 52into a 4-20 milliamp output, which is also the wavelength of a commoncontrol signal.

In another alternative embodiment, the cartridge style hydraulic flowsensor 20 includes a pressure sensor 106 within the interior of thecylindrical casing 66. Alternatively, the pressure sensor 106 may bedisposed on the exterior of the cylindrical casing 66 proximate to thebase 68. The pressure sensor 106 is in communication with the circuitboard 48 and transmitter 38 which will control the communication of adetected pressure within the hydraulic circuit manifold 56 or fluidconduit 108 to the remote controller/processor 76.

In one embodiment, following the receipt of the detected fluid pressurefrom the transmitter 38, the remote controller/processor 76 may manuallyor automatically disengage or activate a pump 86, or other component ofa hydraulic system 84. In the event that the remote controller/processor76 determines that the detected fluid pressure within the fluid conduit108 or hydraulic circuit manifold 56 is above or below a desired fluidpressure, then the remote controller/processor 76 may automaticallyalter the status of a component of a hydraulic system 84 to increase orto decrease the fluid pressure within the fluid conduit 108 or hydrauliccircuit manifold 56 to a desired level.

In another alternative embodiment, the cartridge style hydraulic flowsensor 20 includes a temperature sensor 110. The temperature sensor 110may be located within the interior of the cylindrical casing 66.Alternatively, the temperature sensor 110 may be disposed on theexterior of the cylindrical casing 66 proximate to the base 68. Thetemperature sensor 110 is in communication with the circuit board 48 andtransmitter 38 which will control the communication of a detectedtemperature within the hydraulic circuit manifold 56 or fluid conduit108 to the remote controller/processor 76.

In one embodiment, following the receipt of the detected temperature ofthe fluid from the transmitter 38, the remote controller/processor 76may manually or automatically engage or disengage a component to improvethe operation of the hydraulic system 84. In the event that the remotecontroller/processor 76 determines that the detected fluid temperaturewithin the fluid conduit 108 or hydraulic circuit manifold 56 is aboveor below a desired fluid temperature, then the remotecontroller/processor 76 may automatically alter the status of acomponent of a hydraulic system 84 to increase or to decrease the fluidtemperature within the fluid conduit 108 or hydraulic circuit manifold56 to a desired level.

In at least one embodiment, sufficient electrical shielding is presentbetween the circuit board 48, transmitter 38, Hall Effect Sensor 52,electronic coupler 64, leads 72, pressure sensor 106 and temperaturesensor 110 to prevent electrical interference or feedback between theHall Effect Sensor 52, pressure sensor 106 and temperature sensor 110eliminating erroneous fluid flow, pressure and/or temperaturemeasurements.

In at least one embodiment, the invention does not require that a fluidconduit 108 be cut or breached in order to insert a cartridge stylehydraulic flow sensor into, and the re-plumbing of, a fluid conduit 108.The cartridge style hydraulic flow sensor 20 is replaceable, removableand easily coupled within a cavity 54 of a hydraulic circuit manifold56.

It should be noted that in one or more embodiments the materialsselected to form the cartridge style hydraulic flow sensor 20 may vary.In some embodiments the cartridge style hydraulic flow sensor 20 may beformed of plastic material, metal materials such as steel or stainlesssteel materials, composite materials, coated materials, and othermaterials and combinations of materials dependent upon optimalperformance considerations based on the overall size of the cartridgestyle hydraulic flow sensor 20 to be used and the types of fluid to passthrough the cartridge style hydraulic flow sensor 20. I should be notedthat the material selected to form the cartridge style hydraulic flowsensor 20 will not rust, decay or degrade and fail to operate for theintended purpose when used with a variety of fluids, even where some ofthe fluids are corrosive to some types of materials. It should also benoted that any particular component may be formed of any desiredmaterial for use in the cartridge style hydraulic flow sensor 20, andnot all or the components are required to be formed of an identicalmaterial.

It should be noted that in one or more embodiments the fluids to bemonitored by the cartridge style hydraulic flow sensor 20 are notrestricted to hydraulic (fluid power) applications. The cartridge stylehydraulic flow sensor 20 may be easily utilized in any type of fluidconveying system, where monitoring the rate of fluid flow is desirable.Some limited examples of the types of fluids may include water basedfluids, oil based fluids, flammable fluids, and chemical based fluids toname a few of the numerous types of fluids to be monitored within afluid system.

In at least one alternative embodiment as shown in FIG. 12 through FIG.19 , the cartridge style hydraulic flow sensor is a programmablecartridge style hydraulic flow sensor 120. The programmable cartridgestyle hydraulic flow sensor 120 includes an outer casing 122 having asubstantially cylindrical shape. The cylindrical or outer casing 122includes a inlet fluid conduit 26 and an outlet fluid conduit 22 asearlier described. Fluid flow through the cylindrical or outer casing122 is in the direction of 78.

In one embodiment, the base of the cylindrical or outer casing 122 isidentified by reference numeral 124 which is located within the fluidconduit 108 of a hydraulic circuit manifold 56 in an operative position.

A first seal channel 128 is on the exterior of the cylindrical or outercasing 122 proximate to the base 124. The first seal channel 128receives a first seal 130 which may be an O-Ring to restrict fluidpassage to the exterior of the cylindrical or outer casing 122,directing fluid flow through the inlet fluid conduit 26. The first seal130 is preferably positioned within the first seal channel 128 and isengaged to the interior surface of the fluid conduit 108 of thehydraulic circuit manifold 56 in an operative position.

In an alternative embodiment, an outlet section 132 is preferablylocated above the first seal channel 128. The outlet section 132 is thelocation for the placement of a plurality of outlet fluid conduits 22.In some embodiments the outlet section 132 may be recessed relative tothe exterior surface of the remaining elements of the cylindrical orouter casing 122, having a smaller exterior diameter dimension.

In a preferred embodiment, attachment threads 134 may be disposed on theexterior of the cylindrical or outer casing 122 above the outlet section132. The attachment threads 134 may releasably engage threads (notshown) which may be within the interior of the fluid conduit 108proximate to the exterior of the hydraulic circuit manifold 56.

In at least one alternative embodiment, a second seal channel 136 is onthe exterior of the cylindrical or outer casing 122 above the attachmentthreads 134. The second seal channel 136 receives a second seal 138which may be an O-Ring to restrict fluid passage to the exterior of thecylindrical or outer casing 122, and leaking from the fluid conduit 108of the hydraulic circuit manifold 56. The second seal 138 is preferablypositioned within the second seal channel 136 and is engaged to theinterior surface of the fluid conduit 108 of the hydraulic circuitmanifold 56 in an operative position.

In a preferred embodiment, a casing manifold shoulder 140 is preferablyimmediately above the second seal channel 136. The casing manifoldshoulder 140 functions as an upper compression surface against thesecond seal 138 during the tightening of the attachment threads 134 tothe threads within the fluid conduit 108 of the hydraulic circuitmanifold 56. The squeezing and the expansion of the second seal 138 bythe casing manifold shoulder 140 increases contact between the secondseal 138 and the interior of the hydraulic circuit manifold 56 improvingthe seal and reducing leakage therebetween.

Tightening surfaces 142 may be positioned above the casing manifoldshoulder 140 to assist in the rotation of the cylindrical or outercasing 122 during releasable engagement of the cylindrical or outercasing 122 to the hydraulic circuit manifold 56.

In a preferred embodiment, the interior of the programmable cartridgestyle hydraulic flow sensor 120 and the cylindrical or outer casing 122is preferably substantially cylindrical in shape.

In an alternative embodiment, a first positioning ring groove 144 ispreferably disposed around the circumference of the interior of thecylindrical or outer casing 122 proximate to the base 124. The firstpositioning ring groove 144 receives a first positioning ring 146. Thefirst positioning ring 146 functions as the lower support for the shaftor spindle assembly 148 within the interior of the cylindrical or outercasing 122. The first positioning ring 146 prevents the shaft or spindleassembly 148 from separating from the interior of the bottom of thecylindrical or outer casing 122.

In a preferred embodiment, a sensor shoulder 150 extends inwardly fromthe interior circumference of the cylindrical or outer casing 122 abovethe first positioning ring groove 144. The shaft or spindle assembly 148and the impeller 42 are preferably located between the first positioningring 146 and the sensor shoulder 150. The sensor shoulder 150 functionsas a positioning stop for the Hall Effect Sensor 52 above the impeller42. The sensor shoulder 150 is a sufficient distance above the impeller42 to prevent contact of the tip or lower surface 152 of the Hall EffectSensor 52 with the upper surface of the impeller 42. The sensor shoulder150 preferably engages a lower sensor ledge 176 on the Hall EffectSensor 52, to restrict the descent of the Hall Effect Sensor 52 withininterior of cylindrical or outer casing 122 during assembly of theprogrammable cartridge style hydraulic flow sensor 120.

In at least one alternative embodiment, a circumferential head grove 154is placed around the circumference of the interior wall of thecylindrical or outer casing 122, and is preferably located above thesensor shoulder 150. In at least one embodiment the circumferential headgroove 154 functions as a positioning location for a head nub 156 on theHall Effect Sensor 52.

In some embodiments, a circuit board shoulder 158 extends inwardly fromthe interior circumference of the cylindrical or outer casing 122 abovethe circumferential head groove 154. The circuit board shoulder 158functions as a positioning stop for the circuit board 48 above the HallEffect Sensor 52. The circuit board shoulder 158 is a sufficientdistance above the circumferential head groove 154 and Hall EffectSensor 52 to prevent contact of the circuit board 48 with the uppersurface of the Hall Effect Sensor 52.

In at least one embodiment, a cover shoulder 160 is located above thecircuit board shoulder 158. The cover shoulder 160 extends around thecircumference of the interior of the cylindrical or outer casing 122proximate to the head or top 162. The cover shoulder 160 preferablypositions a cover 164 a sufficient distance above the circuit boardshoulder 158 and the circuit board 48 for the space between the lowersurface of the cover 164 and the upper surface of the circuit board 48to include connecting wires and other electronic components without riskof fracture.

In at least one embodiment, a second positioning ring groove 166 isplaced into the circumference of the interior of the cylindrical orouter casing 122 immediately above the cover shoulder 160 and the cover164, proximate to the head or top 162. A second positioning ring 168 isdisposed in the second positioning ring groove 166 sandwiching the cover164 between the second positioning ring 168 and the cover shoulder 160.

In at least one alternative embodiment, a vertical head channel 170traverses the interior surface of the cylindrical or outer casing 122between the circuit board shoulder 158 and the circumferential headgroove 154, and a portion of the interior surface of the cylindrical orouter casing 122 below the circumferential head groove 154. The verticalhead channel 170 provides space for the passing of the head nub 156during the insertion of the Hall Effect Sensor 52 downwardly from thehead or top 162 towards the impeller 42 within the interior of thecylindrical or outer casing 122.

In at least one embodiment, the interior of the head or top 162 includesa vertical cut-out guide 172 traversing the head or top 162 andextending downwardly to a location immediately above the cover shoulder160. The cut-out guide 172 preferably facilitates the receipt of a tab174 on the cover 164 for positioning of the cover 164 onto the covershoulder 160. (FIG. 14 ) The cut-out guide 172 may also be verticallyaligned with the vertical head channel 170.

In at least one embodiment a shaft or spindle assembly 148 is disposedwithin the interior of the cylindrical or outer casing 122 and is incontact with the first positioning ring 146. The shaft or spindleassembly 148 is substantially cylindrical in shape and is sized forcontact with the interior wall of the cylindrical or outer casing 122.The shaft or spindle assembly 148 includes an enlarged circular basecollar 178. (FIG. 18 ) A plurality of inwardly extending spindlesupports 180 extend from the interior of the base collar 178 to acentral column 182. The spindle supports 180 are integral with both ofthe base collar 178 and the central column 182. In some embodiments,three spindle supports 180 extend from the base collar 178 to thecentral column 182. In alternative embodiments, the number of spindlesupports 180 integral with the base collar 178 and the central column182 may be more or less than three depending on the requirements of aparticular application.

In at least one embodiment the spindle supports 180 define a pluralityof fluid flow passages between adjacent spindle supports 180 interior tothe base collar 178.

In an alternative embodiment, a disc 184 is engaged to the centralcolumn 182 above the spindle supports 180. The disc 184 is preferablycircular in shape and is centrally located within the interior of thecylindrical or outer casing 122. A spindle or shaft 186 extends upwardlyfrom the center of the disc 184 and the central column 182. A shank ofthe spindle or shaft 186 (not shown) is within the interior of thecentral column 182. The spindle or shaft 186 preferably positions, andfunctions as the axis for rotation, for the impeller 42 about thespindle or shaft 186 during operation of the programmable cartridgestyle hydraulic flow sensor 120.

In a preferred embodiment the base collar 178, spindle supports 180,central column 182, and disc 184 may be formed of plastic or compositematerial. Alternatively other materials may be selected for the shaft orspindle assembly 148 dependent upon the requirements of a particularapplication including but not necessarily limited to non-corrosivematerials when exposed to corrosive fluids. Alternatively the basecollar 178, spindle supports 180, central column 182, and disc 184 maybe formed of metal materials such as steel or stainless steel materials,composite materials, coated materials, and other materials andcombinations of materials dependent upon optimal performanceconsiderations for the programmable cartridge style hydraulic flowsensor 120 during use.

In an alternative preferred embodiment, the spindle or shaft 186 isformed of sturdy materials such as metal materials such as steel orstainless steel materials, composite materials, coated materials, andother materials and combinations of materials so long as the spindle orshaft 186 functions as the axis of rotation for the impeller 42 withoutrestricting rotation of the impeller 42 during use.

In at least one embodiment, the impeller 42 is preferably rotatablyengaged to the spindle or shaft 186 and functions as described herein.The impeller 42 preferably includes a plurality of shaped fins or blades196 which upon contact with fluid flow, cause the impeller 42 to freelyrotate about the spindle or shaft 186. In one embodiment, the impeller42 may be formed of plastic or composite material. Alternatively othermaterials may be selected for the impeller 42 dependent upon therequirements of a particular application including but not necessarilylimited to non-corrosive materials when exposed to corrosive fluids. Theimpeller 42 may include internal bearings for engagement to the spindleor shaft 186, to facilitate free rotation between the impeller 42 andspindle or shaft 186.

In at least one embodiment, the top surface of the impeller 42 may beembedded with two slugs 188 of magnetic material. The slugs 188 arepreferably aligned and are positioned on opposite sides of the topsurface relative to the spindle or shaft 186.

In at least one alternative embodiment, the bottom or lower portion ofthe impeller 42 may include a circular outer support 190, an interiorcircular spindle or shaft receiver 192, and a plurality of support ribs194 extending between the circular outer support 190 and the spindle orshaft receiver 192. It should be noted that the impeller 42 may rotateabout the spindle or shaft 186 in either direction.

In at least one embodiment, the Hall Effect Sensor 52 is substantiallycylindrical in shape and is sized for placement within the interior ofthe cylindrical or outer casing 122. The Hall Effect Sensor 52 includesa partially conical lower portion 198 terminating at a flat tip or lowersurface 152. The tip or lower surface 152 is disposed adjacent to thetop of the impeller 42 establishing a desired sensor/impeller separationdimension. The Hall Effect Sensor 52 includes a circular lower sensorledge 176 above the partially conical lower portion 198. The lowersensor ledge 176 is in contact with the sensor shoulder 150 when theHall Effect Sensor 52 is positioned proximate to the impeller 42.

In at least one alternative embodiment, the Hall Effect Sensor 52includes a central portion having a third seal channel 200 and a fourthseal channel 202. A third seal 204 and a fourth seal 206 are preferablydisposed in the respective third and fourth seal channels 200 and 202respectively. The third seal 204 and fourth seal 206 may be O-ringswhich are in flush contact with the interior wall of the cylindrical orouter casing 122 providing a fluid seal, and preventing fluid fromrising within the interior of the cylindrical or outer casing 122 abovethe lower sensor ledge 176.

The Hall Effect Sensor 52 is preferably formed of non corrosive metallicmaterial which does not adversely effect the performance of the sensorin detecting the rate of fluid flow within conduits of a fluid system.

In at least one embodiment, the portion of the Hall Effect Sensor 52immediately above the fourth seal channel 202 includes a flat seat 208.The head nub 156 is preferably disposed centrally on the seat 208. Thehead nub 156 is aligned with the vertical head channel 170 during thedownward insertion of the Hall Effect Sensor 52 within the cylindricalor outer casing 122 into an operative position. The Hall Effect Sensor52 is inserted from the head or top 162 toward the base 124 until thelower sensor ledge 176 contacts the sensor shoulder 150. In thisposition, the head nub 156 will be aligned with and positioned in thecircumferential head groove 154.

In at least one alternative embodiment the top of the Hall Effect Sensor52 is circular in shape with the exception of the flat seat 208. Asensor opening 210 is preferably located centrally through the top ofthe Hall Effect Sensor 52 to provide a passage of electrical wires 212having a suitable electrical connector 214 upwardly to the exterior ofthe Hall Effect Sensor 52.

In some embodiments, upon the engagement of the lower sensor ledge 176to the sensor shoulder 150 a first internal gap is established above thetop of the Hall Effect Sensor 52 and the circuit board shoulder 158. Thefirst internal gap is preferably of sufficient size to hold a portion ofthe electrical wires 212 and any electrical components descending fromthe bottom of the circuit board 48.

In at lease one preferred embodiment, a circuit board 48 is insertedinto the interior of the cylindrical or outer casing 122 and positionedinto contact with the circuit board shoulder 158, following insertion ofthe Hall Effect Sensor 52 within the interior of the cylindrical orouter casing 122. The circuit board 48 is a printed circuit boardincluding a microprocessor 226, a multi-position selector switch 224 onthe upper surface of the printed circuit board, and other electroniccomponents as required on either the top or bottom of he printed circuitboard as convenient for a particular application. The top of the printedcircuit board includes a receiving connector 216 for releasableengagement to connector 214 of the Hall Effect Sensor 52. In additionthe top of the circuit board 48 includes connection wires 218 havinginterface connector 220.

In addition, printed circuit board 48 preferably includes at least oneslot passage 222. The slot passage 222 receives the electrical wires 212from the Hall Effect Sensor 52 enabling the connector 214 to passupwardly past the circuit board 48 for coupling of the connector 214 tothe receiving connector 216.

In a preferred embodiment the circuit board 48 includes on the uppersurface a multi-position selector switch 224. The selector switch 224enables an individual to select up to eight, or more, independentlyprogrammed and/or stored flow passage rates, and one of two voltageoutputs for sensing by the Hall Effect Sensor 52 following positioningof the cylindrical or outer casing 122 within a conduit of a hydrauliccircuit manifold 56.

In at least one embodiment the flow passage rates may be 10, 15, 20, 25,50, 75, 100 & 125 gallons per minute, and the voltage outputs may byeither 0.5-5 vdc or 1-10 vdc. The flow passage rates and/or the voltageoutputs may be conveniently selected by manipulation of the selectorswitch 224 either before or after the programmable cartridge stylehydraulic flow sensor 120 is installed into the a hydraulic circuitmanifold 56 or other fluid system. Available flow options may selectedthough the manipulation of the rotatable dial or selector switch 224 asincorporated into the top of the circuit board 48.

In some embodiments, upon the engagement of the circuit board 48 to thecircuit board shoulder 158 a second internal gap is established abovethe top of the circuit board 48 and below the cover 164. The secondinternal gap is preferably of sufficient size to hold the connectionwires 218, the interface connector 220 and any other electricalcomponents extending upwardly from the circuit board 48.

In at least one embodiment the programmable cartridge style hydraulicflow sensor 120 includes a removable cover 164 which is releasablesecured between the cover shoulder 160 and the second positioning ring168 proximate to the head or top 162. The cover 164 is preferably formedof metallic material and may be formed of non-corrosive metallic orother materials as identified herein dependent upon the requirements ofa particular application.

The cover 164 includes the tab 174 which is aligned with the cut-outguide 172 during the positioning of the cover 164 onto the covershoulder 160, and the engagement of the second positioning ring 168 intothe second positioning ring groove 166 to secure the cover 164 to thecylindrical or outer casing 122.

In at least one alternative embodiment, cover wires 228 descend from thebottom of the cover 164 into the second internal gap. A couplingconnector 230 is engaged to the end of the cover wires 228. The couplingconnector 230 is preferably engaged to the interface connector 220 ofthe circuit board 48. The cover wires 228 preferably traverse through acentrally disposed cover wire passage 232 and are electrically connectedto a communication connector 234 extending upwardly from the top of thecover 164. The communication connector 234 may include a plurality ofconnection prongs at the preference of an individual. In one embodimenta four prong connection may be provided for the communication connector234, where prong 1 is a DCV OUT, prong 2 is a DCV IN, prong 3 isreserved, and prong 4 is Common.

Following assembly of the programmable cartridge style hydraulic flowsensor 120 and the engagement of the programmable cartridge stylehydraulic flow sensor 120 to a hydraulic circuit manifold 56, and theinitiation of operation of a fluid system, the Hall Effect Sensor 52will sense a fluid passage rate and will communicate an electricalsignal representative of the sensed fluid passage rate over theelectrical wires 212, through the connector 214, to the receivingconnector 216 and then to the microprocessor 226 on the circuit board48. A previously selected setting for the selector switch 224 willdirect the sensed fluid passage rate to the appropriate data/processingalgorithm on the circuit board 48 for analysis to determine compliancewith the previously selected setting, or the necessity for a increase ordecrease of the fluid passage rate within the fluid system to complywith the previously selected setting. The determination of fluid flowrate adjustment will then be electrically communicated from theconnection wires 218 to the interface connector 220 and into thecoupling connector 230 and cover wires 228 for communication through thecommunication connector 234 to an appropriate electrical display orreceiver as part of a fluid system control. An individual may thenadjust the fluid passage rate as required. Alternatively, the fluid flowrate may be automatically adjusted in response to the communicated fluidflow rate.

In at least one alternative embodiment, the cover 164 may be releasedfrom the cylindrical or outer casing 122 and the coupling connector 230,and may be disconnected from the interface connector 220. An individualmay then manipulate the selector switch 224 into a different setting forthe programmable cartridge style hydraulic flow sensor 120.

Alternatively an individual may connect a programming device to thecircuit board 48 through connection to the interface connector 220. Anindividual may then reprogram the memory/processing algorithms for themicroprocessor 226 of the circuit board 48 to establish alternativefluid passage rates for detection by the programmable cartridge stylehydraulic flow sensor 120.

The circuit board 48 for the programmable cartridge style hydraulic flowsensor 120 will in some embodiments function utilizing the sameoperations as earlier described for the cartridge style hydraulic flowsensor 20.

Perhaps even more advantageous is that the microprocessor 226 may alsobe pre-programmed at the time of manufacture to modify any of the flowranges to a specific setting and as well as the output signal. Themicroprocessor 226 may also be modified to generate a current output(milliamps) or strictly a pulse output as required for a particularapplication. Programming of the microprocessor 226 may be accomplishedthrough the use of a docking station designed to mate with the printedcircuit board 48 prior to final assembly.

In addition, programming of the microprocessor 226 may be modified at alater date by removal of the cover 164 and the engagement of a dockingstation to a portable or to a desk top personal computer and thenconnection to the interface connector 220. The docking station andcircuit board 48 enable customized programming of the microprocessor 226to satisfy the requirements of a particular application.

In at least one embodiment it is anticipated that the programmablecartridge style hydraulic flow sensor 120 will function without failwhen a fluid within a fluid system traversing through the programmablecartridge style hydraulic flow sensor 120 has an operating temperatureof between approximately −20 degrees C. and up to approximately 125degrees C. It is also anticipated that the programmable cartridge stylehydraulic flow sensor 120 is pressure resistant up to approximately 5000psi. The programmable cartridge style hydraulic flow sensor 120 may alsohave an accuracy of +/−0.5% over the identified full range of operatingtemperatures and pressures identified herein.

It is also anticipated that the fluid within the system including theprogrammable cartridge style hydraulic flow sensor 120 will be HydraulicFluids, Transmission Fluids, Oil-in-Water Emulsions, Water and GlycolMixtures, and Skydrol™ and combinations thereof.

In some embodiments the cylindrical or outer casing 122 is formed ofstainless steel material and the sealing material is formed of Buna,however other materials may function without fail for particularapplications. It is anticipated that the input voltage for theprogrammable cartridge style hydraulic flow sensor 120 will beapproximately 12 to 30 VDC and the output voltage will be approximately0.5 to 5 V or 1-10 V as identified in Chart “A” immediately below.

In at least one embodiment the programmable cartridge style hydraulicflow sensor 120 will have an overall length dimension from the base 124to the tip of the communication connector 234 of approximately 5.03inches or 128.22 centimeters. The width dimension for the interior ofthe cylindrical or outer casing 122 is approximately 1.62 inches or 41.2centimeters.

The performance of the programmable cartridge style hydraulic flowsensor 120 in view of varying pressure and flow rate conditions isidentified below in Graph “A”. In the graph below the real pressure inPSI is indicated on the Y-axis and the Flow Rate in Gallons Per Minute(gpm) is indicated on the X-axis.

In a first embodiment, a cartridge hydraulic flow sensor includes acylindrical casing having an exterior, an interior, a head, and a base,the casing having a first port and a second port through the casing, thefirst port and the second port permitting a fluid to flow into theinterior and out of the interior, the first port being proximate to thebase and the second port being between the head and the first port; asensor is disposed in the interior, the sensor being proximate to thesecond port, the sensor detecting a number of revolutions of a rotatableimpeller rotating about a shaft during a period of time; the shafthaving a first end, the shaft being disposed centrally within theinterior and extending away from the sensor; the rotatable impellerbeing engaged to the first end, the impeller revolving about the shaftfollowing contact with the flow of the fluid; and an electric couplerhaving a transmitter is in communication with the sensor, the electriccoupler being engaged to the head, wherein the sensor communicates tothe transmitter the detected number of revolutions of the impeller aboutthe shaft during the period of time, the transmitter being incommunication with a controller, the transmitter communicating to thecontroller the detected number of revolutions of the impeller about theshaft.

In a second alternative embodiment according to the first embodiment,the sensor includes at least one magnet.

In a third alternative embodiment according to the second embodiment,the cartridge flow sensor is releasably secured within a cavity of ahydraulic circuit manifold.

In a fourth alternative embodiment according to the third embodiment,the flow of the fluid enters into the interior through the first port.

In a fifth alternative embodiment according to the third embodiment, theflow of the fluid enters into the interior through the second port.

In a sixth alternative embodiment according to the third embodiment, theexterior includes threads, wherein the threads secure the cartridgecasing within the cavity of the hydraulic circuit manifold.

In a seventh alternative embodiment according to the third embodiment,the sensor includes a circuit board.

In an eighth alternative embodiment according to the seventh embodiment,the electric coupler is engaged to a platform, the head having a ledge,the platform being supported by the ledge.

In a ninth alternative embodiment according to the eighth embodiment,the electric coupler has leads, the leads providing communicationbetween the transmitter and the controller.

In a tenth alternative embodiment according to the ninth embodiment, thesensor is a Hall Effect Sensor.

In an eleventh alternative embodiment according to the tenth embodiment,the invention includes a check valve, the check valve being disposedproximate to the base, the check valve restricting the flow of the fluidto a single direction within the interior.

In a twelfth alternative embodiment according to the eleventhembodiment, the invention includes a pressure sensor, the pressuresensor being disposed in the interior, the pressure sensor being incommunication with the transmitter, the pressure sensor detecting fluidpressure within a fluid conduit.

In a thirteenth alternative embodiment according to the twelfthembodiment, the invention includes a temperature sensor, the temperaturesensor being disposed in the interior, the temperature sensor being incommunication with the transmitter, the temperature sensor detecting atemperature of the fluid within the interior.

In a fourteenth alternative embodiment according to the thirteenthembodiment, the transmitter communicates to the controller at least twoof the detected number of revolutions of the impeller about the shaft,the detected fluid pressure within a fluid conduit, and the detectedtemperature of the fluid within the interior.

In a fifteenth alternative embodiment according to the fourteenthembodiment, the controller determines a rate of fluid passage within theinterior and the controller communicates at least one of the rate offluid passage, the detected fluid pressure within a fluid conduit, andthe detected temperature of the fluid within the interior to anoperator.

In a sixteenth alternative embodiment according to the fifteenthembodiment, the controller automatically communicates a command signalto at least one component of a hydraulic system for modification of atleast one of the rate of fluid passage, the detected fluid pressurewithin a fluid conduit, and the detected temperature of the fluid withinthe interior.

In a seventeenth alternative embodiment a cartridge hydraulic flowsensor includes a cylindrical casing having an exterior, an interior, ahead, and a base, the casing having a first port and a second portthrough the casing, the first port and the second port permitting afluid to flow into the interior and out of the interior, the first portbeing proximate to the base and the second port being between the headand the first port; a sensor engaged to the head, the sensor detecting anumber of revolutions of a rotatable impeller rotating a shaft during aperiod of time; the shaft having a first end and a second end, the shaftbeing disposed centrally within the interior; the rotatable impellerbeing engaged to the first end, the impeller revolving the shaftfollowing contact with the flow of the fluid; a gear engaged to thesecond end, the gear having a magnetic material, the sensor beingproximate to the gear, the shaft rotating the gear relative to thesensor; and an electric coupler having a transmitter in communicationwith the sensor, the electric coupler being engaged to the head, whereinthe sensor communicates to the transmitter the detected number ofrevolutions of the gear during the period of time, the transmitter beingin communication with a controller, the transmitter communicating to thecontroller the detected number of revolutions of the gear during theperiod of time.

In an eighteenth alternative embodiment, a cartridge style hydraulicflow sensor includes a cylindrical casing comprising an exterior, aninterior, an outlet section, and a base, the casing having a first portand a second port through the casing, the first port and the second portpermitting a fluid to flow into the interior and out of the interior,the first port being proximate to the base and the second port being inthe outlet section, a Hall Effect Sensor is disposed in the interior,the Hall Effect Sensor being proximate to the second port, the HallEffect Sensor detecting a number of revolutions of a rotatable impellerrotating about a shaft during a period of time, the rotatable impellerbeing engaged to a shaft support having the shaft, the impellerrevolving about the shaft following contact with the flow of the fluid,and a cover having a communication connector, the communicationconnector being in communication with a circuit board, the circuit boardbeing in communication with the Hall Effect Sensor, wherein the HallEffect Sensor communicates to the circuit board the detected number ofrevolutions of said impeller about the shaft during the period of time,the circuit board being constructed and arranged to compare the detectednumber of revolutions of the impeller about the shaft during the periodof time to data stored on the circuit board, the circuit boardcommunicating to the communication connector at least one of thedetected number of revolutions of the impeller about the shaft duringthe period of time, the detected number of revolutions of the impellerabout the shaft during the period of time exceeding the data, and thedetected number of revolutions of the impeller about the shaft duringthe period of time being less than the data, and further wherein thecylindrical casing is constructed and arranged for insertion into acavity of a manifold, the cavity being in fluid flow communication witha manifold conduit, the head being proximate to a manifold exterior andthe base being disposed in a manifold interior, the first port and thesecond port being in fluid flow communication with the manifold conduit.

In a nineteenth alternative embodiment according to the eighteenthembodiment, the circuit board further includes a receiving connector, aplurality of connection wires, and an interface connector connected tothe connection wires.

In a twentieth alternative embodiment according to the nineteenthembodiment, the circuit board further includes a selector switch, amicroprocessor and memory.

In a twenty-first alternative embodiment according to the twentiethembodiment, the data is stored on the memory and the microprocessorcompares the detected number of revolutions of the impeller about theshaft during the period of time to the data.

In a twenty-second alternative embodiment according to the twenty-firstembodiment, the data comprises a plurality of individual fluid flowinformation parameters, and further wherein the selector switch directsthe microprocessor to at least one of the plurality of individual fluidflow information parameters.

In a twenty-third alternative embodiment according to the twenty-secondembodiment, the interior further includes at least one of a sensorshoulder and a circuit board shoulder.

In a twenty-fourth alternative embodiment according to the twenty-thirdembodiment, the exterior further includes at least one of a first sealchannel and a second seal channel.

In a twenty-fifth alternative embodiment according to the twenty-fourthembodiment, the at least one casing exterior seal is disposed in atleast one of the first seal channel and the second seal channel.

In a twenty-sixth alternative embodiment according to the twenty-fifthembodiment, the Hall Effect Sensor additionally includes a Hall EffectSensor exterior, the Hall Effect Sensor exterior having at least one ofa third seal channel and a fourth seal channel.

In a twenty-seventh alternative embodiment according to the twenty-sixthembodiment, the at least one Hall Effect Sensor exterior seal isdisposed in at least one of the third seal channel and the fourth sealchannel.

In a twenty-eighth alternative embodiment according to thetwenty-seventh embodiment, the interior has the circuit board shoulder,the circuit board engaging the circuit board shoulder.

In a twenty-ninth alternative embodiment according to the twenty-eighthembodiment, the circuit board has at least one slot passage.

In a thirtieth alternative embodiment according to the twenty-ninthembodiment, the shaft support has a base collar, at least two spindlesupports, and a central column.

In a thirty-first alternative embodiment according to the thirtiethembodiment, the interior has the sensor shoulder, the Hall Effect Sensorexterior having a lower sensor ledge, the lower sensor ledge engagingthe sensor shoulder.

In a thirty-second alternative embodiment according to the thirty-firstembodiment, the Hall Effect Sensor exterior has a head nub.

In a thirty-third alternative embodiment according to the thirty-secondembodiment, the cartridge hydraulic flow sensor includes a pressuresensor, the pressure sensor being disposed in the interior, the pressuresensor detecting fluid pressure within the manifold conduit.

In a thirty-fourth alternative embodiment according to the thirty-thirdembodiment, the cartridge hydraulic flow sensor includes a temperaturesensor disposed in the interior, the temperature sensor detecting atemperature of the fluid within the interior.

In a thirty-fifth alternative embodiment according to the thirty-fourthembodiment, the circuit board communicates at least two of the detectednumber of revolutions of the impeller about the shaft, the detectedfluid pressure within the manifold conduit, and the detected temperatureof the fluid within the interior.

In a thirty-sixth alternative embodiment according to the thirty-fifthembodiment, the circuit board automatically communicates a commandsignal to at least one component of a hydraulic system for modificationof at least one of a rate of fluid passage, the detected fluid pressurewithin the manifold conduit, and the detected temperature of the fluidwithin the interior.

This completes the description of the preferred and alternateembodiments of the invention. Those skilled in the art may recognizeother equivalents to the specific embodiment described herein whichequivalents are intended to be encompassed by the claims attachedhereto.

The above disclosure is intended to be illustrative and not exhaustive.This description will suggest many variations and alternatives to one ofordinary skill in this art. The various elements shown in the individualfigures and described above may be combined or modified for combinationas desired. All these alternatives and variations are intended to beincluded within the scope of the claims where the term “comprising”means “including, but not limited to”.

These and other embodiments which characterize the invention are pointedout with particularity in the claims annexed hereto and forming a parthereof However, for further understanding of the invention, itsadvantages and objectives obtained by its use, reference should be madeto the drawings which form a further part hereof and the accompanyingdescriptive matter, in which there is illustrated and describedembodiments of the invention.

With respect to the above description, it is to be realized that theoptimum dimensional relationships for the parts of the invention, toinclude variations in size, materials, shape, form, function and mannerof operation, assembly and use, are deemed to be within the expertise ofthose skilled in the art, and all equivalent structural variations andTherefore, the foregoing is considered as illustrative only of theprinciples of the invention. Further, since numerous modifications andchanges will readily occur to those skilled in the art, it is notdesired to limit the invention to the exact construction and operationshown and described, and accordingly, all suitable modifications andequivalents may be resorted to, falling within the scope of theinvention.

I claim:
 1. A cartridge hydraulic flow sensor comprising: a cylindricalcasing comprising an exterior, an interior, an outlet section, and abase, said casing having a first port and a second port through saidcasing, said first port and said second port permitting a fluid to flowinto said interior and out of said interior, said first port beingproximate to said base and said second port being in said outletsection; a Hall Effect Sensor disposed in said interior, said HallEffect Sensor being proximate to said second port, said Hall EffectSensor detecting a number of revolutions of a rotatable impellerrotating about a shaft during a period of time; said rotatable impellerbeing engaged to a shaft support having said shaft, said impellerrevolving about said shaft following contact with said flow of saidfluid; and a cover having a communication connector, said communicationconnector being in communication with a circuit board, said circuitboard being in communication with said Hall Effect Sensor, wherein saidHall Effect Sensor communicates to said circuit board said detectednumber of revolutions of said impeller about said shaft during saidperiod of time, said circuit board being constructed and arranged tocompare said detected number of revolutions of said impeller about saidshaft during said period of time to data stored on said circuit board,said circuit board communicating to said communication connector atleast one of said detected number of revolutions of said impeller aboutsaid shaft during said period of time, said detected number ofrevolutions of said impeller about said shaft during said period of timeexceeding said data, and said detected number of revolutions of saidimpeller about said shaft during said period of time being less thansaid data, and further wherein said cylindrical casing is constructedand arranged for insertion into a cavity of a manifold, said cavitybeing in fluid flow communication with a manifold conduit, said headbeing proximate to a manifold exterior and said base being disposed in amanifold interior, said first port and said second port being in fluidflow communication with said manifold conduit.
 2. The cartridgehydraulic flow sensor according to claim 1, said circuit board furthercomprising a receiving connector, a plurality of connection wires, andan interface connector connected to said connection wires.
 3. Thecartridge hydraulic flow sensor according to claim 2, said circuit boardfurther comprising a selector switch, a microprocessor and memory. 4.The cartridge hydraulic flow sensor according to claim 3, wherein saiddata is stored on said memory and said microprocessor compares saiddetected number of revolutions of said impeller about said shaft duringsaid period of time to said data.
 5. The cartridge hydraulic flow sensoraccording to claim 4, wherein said data comprises a plurality ofindividual fluid flow information parameters, and further wherein saidselector switch directs said microprocessor to at least one of saidplurality of individual fluid flow information parameters.
 6. Thecartridge hydraulic flow sensor according to claim 5, said interiorfurther comprising at least one of a sensor shoulder, a circumferentialhead groove, and a circuit board shoulder.
 7. The cartridge hydraulicflow sensor according to claim 6, said exterior further comprising atleast one of a first seal channel and a second seal channel.
 8. Thecartridge hydraulic flow sensor according to claim 7, wherein at leastone casing exterior seal is disposed in at least one of said first sealchannel and said second seal channel.
 9. The cartridge hydraulic flowsensor according to claim 8, said Hall Effect Sensor further comprisinga Hall Effect Sensor exterior, said Hall Effect Sensor exterior havingat least one of a third seal channel and a fourth seal channel.
 10. Thecartridge hydraulic flow sensor according to claim 9, wherein at leastone Hall Effect Sensor exterior seal is disposed in at least one of saidthird seal channel and said fourth seal channel.
 11. The cartridgehydraulic flow sensor according to claim 10, said interior having saidcircuit board shoulder, said circuit board engaging said circuit boardshoulder.
 12. The cartridge hydraulic flow sensor according to claim 11,said circuit board having at least one slot passage.
 13. The cartridgehydraulic flow sensor according to claim 12, said shaft support having abase collar, at least two spindle supports, and a central column. 14.The cartridge hydraulic flow sensor according to claim 13, said interiorhaving said sensor shoulder, said Hall Effect Sensor exterior having alower sensor ledge, said lower sensor ledge engaging said sensorshoulder.
 15. The cartridge hydraulic flow sensor according to claim 14,said Hall Effect Sensor exterior having a head nub.
 16. The cartridgehydraulic flow sensor according to claim 15, further comprising apressure sensor, said pressure sensor being disposed in said interior,said pressure sensor detecting fluid pressure within said manifoldconduit.
 17. The cartridge hydraulic flow sensor according to claim 16,further comprising a temperature sensor disposed in said interior, saidtemperature sensor detecting a temperature of said fluid within saidinterior.
 18. The cartridge hydraulic flow sensor according to claim 17,wherein said circuit board communicates at least two of said detectednumber of revolutions of said impeller about said shaft, said detectedfluid pressure within said manifold conduit, and said detectedtemperature of said fluid within said interior.
 19. The cartridgehydraulic flow sensor according to claim 18, wherein said circuit boardautomatically communicates a command signal to at least one component ofa hydraulic system for modification of at least one of a rate of fluidpassage, said detected fluid pressure within said manifold conduit, andsaid detected temperature of said fluid within said interior.